DRIVES, CONTROLS & MOTORS FEATURE Driving ErP forward
From 1st January 2017, all electric motor units will be subject to minimum levels of efficiency under the requirements of the Ecodesign Directive (commonly referred to as the Energy-related Products – or ErP – Directive), affecting a huge 70% of the commercial sector. Here, Mark McCall, product marketing manager at Newey & Eyre, considers the implications of this new legislation for engineers
W
hile there is strong evidence that the UK has made enormous
improvements over recent years in reducing carbon emissions from industrial premises, there is still much work to be done. This is evidenced by the fact that the UK’s industrial sector still ranks in the top three for carbon emissions in Europe, alongside Germany and Italy. One piece of legislation designed to
tackle this situation is the ErP Directive which applies across energy-related products (defined as products that use energy or have an indirect impact on energy consumption) sold in the commercial and industrial sectors in the European Economic Area. The next wave of ErP requirements targets electric motors in the industrial setting – not surprising, since within industrial manufacturing, electrical motors account for the lion’s share of electrical energy consumption. From January 1st 2017, all squirrel cage motors with a rated output of 0.75 to 375kW must either be supplied as an IE3 efficiency motor or as an IE2 efficiency motor with a variable speed drive (VSD). Choice of drive engineering is dependent on the application. Where fixed speeds or lower switching frequencies are involved, standard motor starters offer a lower installation cost solution; whereas VSDs are more appropriate for applications with variable speeds or frequently alternating loads. While IE3 premium efficiency
fixed-speed motors deliver the energy savings, these are characterised by properties including higher starting currents, which means that it is particularly important to use high- quality switchgear and protection components with the correct trip pattern and with a switching duty specifically designed for the IE3 motor being used. IE3 motors achieve the required energy
savings, but can be more expensive to purchase. Standard motor starting and soft start are appropriate in fixed speed
and machinery damage during start up, running and shutdown. Traditionally, VSDs have mostly been
specified when part of a larger or more complex control system, chiefly due to a gap in the market for an enclosed direct online (DOL) product that incorporates the benefits of a VSD. Newey & Eyre has addressed this gap by developing the Newlec EcoStart, an energy-efficient enclosed motor starter that offers all of the benefits of a VSD and can be combined with an ErP-compliant IE2 motor to meet the new directives. In many instances, motors are over-
rated for their application and the speed can be reduced to deliver energy savings. As an out-of-the-box solution, EcoStart is supplied to run at 85% motor speed which immediately provides up to 40% electrical energy savings. Additionally, it can be set to operate precisely to the requirements of the individual application. As an example, with a 4kW EcoStart
control applications where load demands maximum motor speed, or mechanical constraints do not permit speed variation. Low voltage switchgear in a well- designed system can achieve significant energy savings, but these relate directly to the amount of time the motor is switched off. This can either involve the simple expedient of switching systems off when they are not needed, or designing
The ErP Directive applies across energy-related products – defined as products that use energy or have an indirect impact on energy consumption
motor with three-phase inverter, set to run at 85%, in a system that is operational for 12 hours a day, 250 days a year, with an electricity cost of 12 pence per kW/h, the user could expect to save £836 per annum on energy bills with a payback period of 1.5 years.
DELIVERING SOLUTIONS The specific application will determine the choice of motor, with the greater costs of higher efficiency motors being offset by the ongoing savings that can be made in energy costs with the correct choice. ErP compliance gives engineers the baseline in terms of the
“The next wave of ErP requirements targets electric motors in the industrial setting –not surprising, since within industrial manufacturing, electrical motors account for the lion’s share of electrical energy consumption”
an intelligent system incorporating techniques for determining precisely when the motor needs to be operational.
SAVING ENERGY Alternatively, significant savings can be achieved by using an IE2 motor with a VSD. In many applications, particularly centrifugal fans and pumps, compressors and material handling, the energy savings alone provide a conclusive argument for the incorporation of a motor with a VSD. For example, in many fan and pump applications, efficiency gains of between 20% and 70% can be achieved. Other benefits also include increased motor longevity, reduced maintenance and a reduced risk of motor
minimum permitted efficiency and creates the opportunity to deliver solutions that can lead to lower running and energy costs, reduced maintenance and overall system downtime.
Newey & Eyre T: 0800 783 6909
www.neweyandeyre.co.uk
The next wave of ErP requirements targets electric motors in the industrial setting
DESIGN SOLUTIONS | JUNE 2016 29
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